Deep cell egg carton



April 1966 Y A. E. RANDLES, JR 3,244,349

DEEP CELL EGG CARTON Filed Feb. 21, 1964 5 Sheets-Sheet l l I I /26 P 44 INVENTOR FIG. .1. ARTHUR E. RANDLES,JR.

svg' g a zi ATTORNEYS April 5, 1966 A. E. RANDLES. JR 3,244,349

DEEP CELL EGG CARTON Filed Feb. 21, 1964 5 Sheets-Sheet 2 FIG. 3

INVENTOR ARTHUR E. RANDLES,JR.

BY M )3 h ATTORNEYS April 5, 1966 A. E. RANDLES, JR

DEEP CELL EGG CARTON Filed Feb. 21, 1964 5 Sheets-Sheet 5 FIG. 4

INVENTOR ARTHUR E. RANDLE$,JR. M 592 ATTORNEYS April 5, 1966 A. E. RANDLES, JR 3,244,349

DEEP CELL EGG CARTON Filed Feb. 21, 1964 5 Sheets-Sheet 4 23 INVENTOR ARTHUR E. RANDLES,JR.

svwad 93 ATTORNEYS A ril 5, 1966 A. E. RANDLES, JR 3,244,349

DEEP CELL nee CARTON Filed Feb. 21, 1964 5 Sheets-Sheet 5 INVENTOR ARTHUR E. RANDLES,JR

ATTORNEYS I wardly directed,

United States Patent 3,244,349 DEEP CELL EGG CARTON Arthur E. Handles, Jr., 3000 Middleiield Road, Redwood City, Calif. Filed Feb. 21, 1964, Ser. No. 346,511 1 Claim. (Cl. 22928) This invention relates to an egg carton and, more particularly, to an egg carton blank that is compact and easily handled and the carton product thereof which is of rigid construction and adapted to accommodate and provide protective support for even the largest size eggs.

Cellular cartons for packing eggs and the like are commonly formed from a single sheet of a material such as fiberboard which is scored along a plurality of fold lines to form a series of panels including a cover, front and rear Wall panels, forward and rear bottom panels and upinterconnected longitudinal divider panels. The divider panels separate the carton into two parallel rows of cells or nests which are further divided by a plurality of general upright cross partitions. Generally, the cross partitions are formed from a panel that extends from the top of the front panel and is adhesively attached to the rear panel. Since it is desirable to have the carton blanks as flat and compact as possible, it is obvious that considerable care must be taken in the design of the carton so that a group of panels at one end of the die cut blank will be identical in Width to the next group of panels so that when it is folded over and the cross partition panel is adhesively attached, the carton blank will lie flat. In the case of the type of carton previously described generally and having two wall panels, two bottom panels, two upright longitudinal divider panels and a single panel from which the cross partitions are formed extending between the front and rear panels there are an odd number of panels and the total Width of three panels must be equal to the total width of the remaining four panels in order for the blank to be folded over and lie flat.

Also in the previous egg cartons it was necessary to restrict the height of the front and rear panels so that a portion of the egg extended about them to facilitate removal of the eggs.

It is, therefore, an object of this invention to provide a carton that will accommodate and fully enclose even the largest size eggs.

It is a further object of this invention to provide a carton blank that may be folded into an extremely compact form to facilitate handling and packing.

It is a further object of this invention to provide a carton blank comprising essentially just four panels so that prior to assembly the carton blank may be collapsed into a relatively flat parallelogram.

It is a further object of this invention to provide a carton blank comprising essentially four panels whereby modifications in sizes can be made without upsetting the balance of the carton blank.

It is a further object of this invention to provide an improved carton lock that permits inter-engagement of the cover and front panels without contacting eggs contained therein.

It is a further object of this invention to provide an egg carton including cells that completely enclose eggs packed therein but provide support for the eggs of maximum resilience so as to minimize breakage.

It is a further object of this invention to provide an egg carton that completely encloses eggs packed therein but includes means to facilitate removal thereof.

In carrying out this invention, I provide a carton blank having essentially four panels in addition to the cover, a top, cross partition panel, front and rear wall panels and the bottom panel. This is accomplished without sacrificing the central, longitudinal divider panel by providing a blank that, as cut, has hingedly connected divider panels interposed between the front and rear bottom panel. Then, in forming the carton blank, the bottom panels are brought together to form a continuous panel and the central divider panels are glued together in face to face relationship. The front and rear wall panels are substantially the same width and, since the cross partition panel is equal to the total width of the bottom panel, the blank forms essentially a collapsed parallelogram with adhesively attached central divider panels extending inside of the parallelogram. With the cover panel folded over the top of the collapsed parallelogram, an extremely compact blank results. In assembly, the parallelogram is opened into a rectangle and the longitudinal divider panels inherently assume an upright position to receive the cross partitions which are folded down into inter-locking engagement therewith.

Other objects and advantages of this invention will become apparent from the description following when read in conjunction with the accompanying drawings wherein:

FIG. 1 is a plan view of a die cut egg carton blank;

FIG. 2 is a partial perspective view of a portion of the egg carton blank showing an intermediate step of assembly;

FIG. 3 is a view in perspective showing the carton blank after the intermediate step of assembly;

FIG. 4 is a view in perspective showing the carton blank showing the final step of assembly;

FIG. 5 is a view in perspective of the completed carton blank;

FIGS. 6, 7 and 8 are perspective views showing steps of erecting and packing an egg carton from the egg carton blank;

FIG. 9 is an end view of the assembled and closed egg carton;

FIG. 10 is a section view taken along lines Ill-10 of FIG. 9; and

FIGS. 11 and 12 are partial views in perspective and in section respectively, showing the cover locking means.

Referring now more particularly to FIG. 1, the carton blank 10 as initially die cut comprises, viewing from top to bottom, a cover panel 12, the rear wall panel 14, a rear bottom panel 16, central divider panels 18 and 20, a forward bottom panel 22, a front wall panel 24, a cross partition panel 26 an attachment strip 28. These panels are formed from a single sheet of material such as fi'berboard, and in the order designated are connected together along foldable score lines 13, 15, 17, 19, 2 1, 23, 25, and 27, respectively.

At the upper end of the cover panel 12 are formed six locking tabs 30 each of which is attached to cover panel along a score line 32. A small separator tab 54 extends between each locking tab, interrupting the score line 32. The separator tabs 34 remain co-planar with the cover panel 12 and do not fold with the locking tabs 30 for a purpose hereinafter to be described. The separator tabs 34 are separated from one adjacent 'cover tab by a transverse cut 36 intersecting the score line 32 and from the other tab 30 by a parallel out 37 extending parallel to the score line 32 and then curving in at 38 to intersect the score lines.

Extending from each of the central divider panels 18 and20 are a number of tabs 40 and 42 which are uninterrupted by a score line so that as the central panels are folded along a score 17 and 21, the tabs 40 and 42 will remain in the plane of the integral central divider panel 18 or 20.

The cross partition panel 26 is die cut into a plurality of cross partitions 44 which form transverse rows of cells. There being normally 7 cross partitions which form six rows of cells. The cross partitions are hingedl'y connected at score lines 46 to the connector tabs 4-8 which, in turn, are hingedly connected at score lines 25 and 27 to the front panel and attachment strip 23, respectively. The cross partitions 44 are notched at St) and '52 at top and bottom for interlocking engagement with the central divider panel and the attachment strip, respectively.

Referring now to FIGS. 2 and 3 there is shown the first stage in the formation of the carton blank. As shown there, the central divider panels are folded together along the score line 19 interconnecting them with the adhesive areas in contact so that they are firmly united in face to face engagement. Thus, the divider panels form a two-ply separator, with the score lines 17 and 21 connecting the divider panels to the front and rear bottom panels being brought together so that the bottom panels form, in effect, a single continuous panel as shown in FIG. 3. With the central divider panels 13 and 20 secured together, it will be noted that the carton blank cornpnises essentially four panels, i.e. the front panel 24, the rear panel 14, the continuous bottom panels 18 and 20 and the partition panel 26.

Referring now to FIGS. 4 and 5, after the longitudinal divider panels are adhesively united, the blank is inverted so that the adhesive 56 on the attachment strip is face down and then the partition panel 26 is folded over at the score line 25 so that the attachment strip 28 is again face up. Finally, the back and cover panels are folded over along score line 15 so that the rear Wall panel 14 is adhesively attached to the attachment strip 28 along the score line 13. It will be noted that the front wall panel 24 and carton bottom 16, 22 are disposed on the bottom and the cross partition panel 26 and attachment strip are folded over them. The top layer of the extremely compact blank is formed by the rear wall 14 and the cover panel 12. The compactness of the arrangement is advanced by reason of the fact that the attachment strip 28 is not folded back on panels 14 or 12 but lies flat in the plane of partition panel 25. Preferably, the front and rear walls 24 and 14 are of the same width and the partition panel 2 6 is equal in Width to the continuous bottom panels 16, 22 so that the score line 27 between the partition panel 26 and the attachment strip 28 lies directly along the score line 13 when the attachment is elfected. Since the cover panel 12 is substantially of the width of the cross partition panel 26, the entire blank when folded forms a very compact assembly only slightly Wider than the combined width of any of the pairs of adjacent panels formed, i.e. panels 24 and 16, 22 and panels '14 and '26 (or 12).

Referring now to FIGS. 6 to 9, the carton blank may be erected into an egg carton first by opening the collapsed parallelogram of FIG. into a rectangle with the front and rear walls 24 and 14 and the two-ply divider panels '18 and 20 upright. Then, the cross partitions 44 are folded downwardly into the V-slots 60 opening into the central divider panels until the notches 5'0 and 52 are brought into interlocking engagement with the hook 62 and the bottom 64 of the V-slo-t 60. The notches 50 and 52 accept the hook 62 and the slot bottom rather snugly so that the assembly is extremely rigid. The two-ply central divider panel 18, 20 is preferably of a height so that, with the depending tabs 40 and 42 engaging the supporting surface, the top edge along the score 19 is approximately in the plane of the top edges 27 and 13 of the front and rear panels 24 and 14. Since the lower edges of the tabs 4-2 and 40 form supporting surfaces, the bottom panels 16 and 22 slope upwardly from the score lines 15 and 23 connecting them with the rear and front panels "14 and 24, to their connection with the two-ply separator panels 18 and 24 above the tabs 40 and -42. The displacement of the bottom panels above the support surfaces serves to cushion the eggs from contact with a table or other surface upon which they might be placed.

Because there is no limitation upon the height of the front and rear panels 14 and 24 because of a need to balance the dimensions of other panels, they are desirably made, as shown in FIG. 9 higher than the length of the major axis of an egg so that the egg is completely enclosed within the protective upright walls 14, 24 and 18, 2t) and suspended out of contact with any surface upon which the carton 14 is supported or from any article to be supported thereby. As shown most clearly in FIGS. 1 and 3, removal of the eggs is facilitated by means of flaps 66 which are cut from the deep cells by pushing upwardly through the bottom. Additionally, the flaps 66 provide a resilient support for the eggs While packed to cushion them against shock. As a further feature of this carton, the lower edges 68 of the partitions 44 are displaced above the bottom panels 16 and 22 by an amount sufficient to provide a space through which one may insert his fingers to remove eggs progressively along the length of the carton starting with one of the end cells.

It will be noted also that, since the cross partitions 44 are hingedly connected only at the extreme upper edge of the front panel '24 and, by connection of the attachment strip along the score line 13, only to the upper edge of the rear wall, the cross partitions 44 are yieldable over their full depth from a point above the top of the eggs, except for the interlocking engagement between the twoply longitudinal divider 18, 20 and the cross partitions 44. This provides an additional cushioning elfect for eggs contained within the carton cells.

As previously described, there are six locking tabs 30 at the end of the cover panel 12, one for insertion into each of the six front cells into which the carton is divided. Referring to FIGS. 11 and 12, the formation of the divider tab 34 between locking tabs 30 provides an effective lock that is easily formed and reliable in operation. Specifically, when originally die cut, the material from the V-shaped entry notch 33 is all that need be stripped away and it may be stripped directly away by pulling in the plane of the lock tabs 30 without punching or bending. Then with the cut 37 which forms the end of the separator tab being cut parallel and below the score line 32, a small slot 34a is inherently formed below the divider tab 30 as the interlocking tab 34 is folded downward out of the plane of the cover panel 12 in which the separator tab 34 remains. Each of these slots received a connecting strip 48 which secures the transverse partition 44 to the front panel 24 securely locking the cover panel 12 in place. Because the top edge of the front panel 24 extends above the top of an egg contained within the cell this locking may be effected without contasting the egg at all since a susbtantial free space is provided at the upper front corner of the carton as shown in FIG. 9.

While this invention has been described in connection with a preferred embodiment thereof, it is apparent that modifications and changes therein may be made by those skilled in the art Without departing from the spirit and scope of this invention as defined by the claim appended hereto.

Having described my invention, I claim:

A cellular carton for eggs or the like comprising:

generally upright front and rear Walls, each of a height greater than the length of the major axis of an egg, forward and rear bottom panels connnected along fold lines to said front and rear Walls, respectively,

an upright central divider panel intermediate said front and rear walls,

a series of upright cross partitions extending transversely between said front and rear Walls,

interlocking means on said central panel and at least some of said cross partitions inter-engaged against relative movement therebetween,

lower edges of said central panel terminating substantially in the plane of said fold lines to form a carton support,

the upper edges of said central panel and said front and rear Walls being substantially parallel and co-planar,

a top panel hingedly connected to the upper edge of said rear wall,

a closure fiap hingedly connected to said top panel along a fold line, and

complementary interlocking means on said top panel at said fold line and on said front Wall at the upper edge thereof.

References Cited by the Examiner UNITED STATES PATENTS JOSEPH R. LECLAIR, Primary Examiner. FRANKLIN T. GARRETT, Examiner. 

